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R. P. HEUER March 10, 1964 ENCASED PLURAL VBASIC REFRACTOR BRICK ELEMENTS '2 Sheets-Sheet 1 Filed Sept. 9, 1960 United States Patent O 3,123,940 ENCASED FLURAL BASIC REFRACTR BRICK ELEMENTS Russell Pearce Heuer, Villanova, Pa., assigner to General Refractories Company, a corporation of Pennsylvania Filed Sept. 9, 1960, Ser. No. 55,046 Claims priority, application Canada Jan. 16, 1960 3 Claims. tCl. Sti-416) The present invention relates to the manufacture of brick which have external metallic plates.

The present application is a continuation-impart of my U.S. patent application Serial No. 794,379, led February 19, 1959, for Basic Refractory Brick and Method, now Patent 3,089,284, issued May 14, 1963.

A purpose of the invention is to minimize the use of double thicknesses of metallic plates on the outsides of basic refractory bricks.

A further purpose is to obtain rm attachment of oxidizable metallic plates to a basic refractory brick without the necessity of comolding more than one plate, and at the same time cover all four lateral faces of the brick to at least a major extent.

A further purpose is to enclose a plurality of bricks in a second oxidizable metallic plate which surrounds the group and is secured to a first oxidizable metallic plate which itself is fastened to one of the bricks of the group.

A further purpose is to hold a hanger in position with respect to two or more bricks in a group by securing a second plate around the group of bricks which itself is fastened to a first plate secured to one of the bricks.

Further purposes appear in the specification and in the claims.

In the drawings I have chosen to illustrate a few only of the numerous embodiments in which the invention may appear, selecting the forms shown from the standpoints f convenience in illustration, satisfactory operation and clear demonstration of the principles involved.

FIGURE 1 is a plan view of a blank from which the comolded plate is formed.

FIGURE 2 is a perspective of one form of comolded plate.

FIGURE 3 is a perspective of a Variant form of comolded plate.

FIGURE 4 is a diagrammatic vertical section showing the comolding of the refractory and the plate.

FIGURES 5 to 8 illustrate a variation of the invention, in which an oxidizable metallic plate surrounds a group Of bricks.

FIGURE 5 is a transverse section through a group of bricks according to the invention surrounded by an external plate.

FlGURE 6 is an exploded perspective showing the assembly of the bricks of FIGURE 8 with the surrounding plate and the hanger.

FIGURE 7 is a perspective of a completed group of bricks and the surrounding plate and hanger according to FIGURE 8.

FIGURE 8 is a section on the line 8 8 of FIGURE 6.

FIGURE 9 is a cross section similar to FIGURE 5 of two bricks surrounded by a plate structure showing a modification.

Describing in illustration but not in limitation and referring to the drawings:

Extensive use is being made in refractory roofs and other constructions of basic refractory brick provided with oxidizable metallic plates on the outside, and in some cases also on the inside of the bricks.

The plates are usually of steel, preferably plain carbon steel such as AISI 1010 or 1035 or suitably low alloy steel. The plates are normally in the range of thickness between 3/32" and 1A", and are suitably ailixed to the 3,123,040 Patented Mar. 10, 1964 ice refractory of the brick. In furnace use the plates oxidize and react with the refractory, improving the behavior of the refractory roof as a whole.

One method of making such brick includes molding the brick and then aflixing to the outside of the brick two opposed channel-shaped plates each of which covers one of the two parallel major lateral faces and two parallel minor lateral faces. On the minor lateral faces the arms of the channel overlap and the plates are welded together and prevented from slipping off the brick by punching holes in the brick and lancing tongues of metal from the plates which fit into such holes.

This procedure is cumbersome, and produces a brick in which the plates are not always tightly held to the refractory. It furthermore is subject to the serious disadvantage that on the minor lateral surfaces of each brick there are two layers or thicknesses of metal of the plate.

By the present invention it is possible to greatly reduce the use of double thicknesses of metal plate, thus avoiding the likelihood that metal may melt and leave the joint rather than oxidize and react with the refractory.

By the invention it is possible to join together a group of bricks.

I illustrate in FIGURES 1 and 2 a plate 20 which in FIGURE l is in the form of a blank having a body portion 21 which is intended to extend along the major portion of one lateral surface of the brick, and having projecting portions or tabs Z2 which are adapted to be bent up suitably to an angle somewhat greater than a right angle as shown in FIGURE 2.

There are also projections 23 lanced out from the base portion of the channel of the oxidizable metallic plate, and capable of being embedded into the refractory by comolding.

The plate 20 is placed in a mold as shown in FIGURE 4 resting on the bottom die 24 with the tabs or arms 22 of the channel extending upward and the projections 23 extending upward. The base of the channel is narrower than the mold and the upper ends of the tabs 22 spring engage the side walls 25 of the mold. The mold has an upper die 26 which in molding moves relatively toward the lower die.

A mass of basic refractory mixture 27 is placed in the mold of FIGURE 4.

The refractory mixture may be any suitable basic refractory such as chrome-magnesia or magnesia-chrome, many such refractory mixtures having been described in my prior patents.

The upper and lower dies 26 and 24 move relatively together, applying a molding pressure which should exceed 3000 p.s.i. and preferably should exceed 10,000 psi. or 15,000 psi. The effect is to produce a brick Z8, fwhich has a refractory body `and a comolded plate 20, with the tabs Z2 at the outside extending only a short distance over the lateral faces 30, suitably not more than one-fourth of the lateral faces. The base of the channel 21 cove-rs the major portion and in the actual brick y.substantially all of ythe major lateral face 31. It will also be noted that the tabs Z2 are separated in the preferred embodiment by refractory areas 32 where no tabs are present at each one of the faces 30.

While .the angle of vthe tabs to the base of the channel exceeded in FIGURE 4 prior to molding, and .the Width of the iba-se of the channel is smaller than the intended corresponding side of the formed brick, after molding the tabs are formed at right yangles to the base Z1 of the channel in the formed 1brick las a result of the molding pressure. The projections 23 of course are firmly anchored in the interior of the brick by comolding.

In some cases it is desirable to use an internal plate cornolded with the brick in accordance with my U.S.

Patent No. 2,791,116. In FIGURE 3 I illustrate an internal oxidizable metallic plate 33 of channel-shaped form having a base 34 which is united to the base 2l of the channel and having arms 3S of the channel which are embedded in the interior of the brick. In the plate of FIGURE 3 the base 34 of the channel of the internal plate is desirably united to the base 21 of the channel of the external plate as by spot welding as shown at 36.

In the form of FiGURES to 8, a group, suitably a pair, of basic refractory bricks is associated together as a single unit. One brick 28 has a comolded plate 20 as already described on the major portion of one lateral face, and this brick also has a cornolded oxidizable metallic plate 43 on the surface of the brick 2S which is remote from the base portion 2i of the plate 20. There are suitable tabs 44 on the plate 43 which are buried in the refractory by comolding and the plate 43 extends over the major portion of the face 45 of the brick 28, being terminated at the cold end short of the hanger recess 46 which receives hook end 47 of double hook metallic hanger 4S.

A second cooperating basic refractory brick 28 is placed with one major lateral face against the major lateral face 45 of the brick ZS. 'Ilhe brick 28 as molded is entirely free from comolded plates but rests against the outside yof the plate 43.

Brick 28 has a cooperating hanger recess 46 at the side near the cold end which receives a cooperating hook 47 on the hanger, there rbeing adequate space in the hanger recess to allow .the shank 56 of the hanger 41S to protrude beyond the cold end and provide an eye 51 which will receive a suspension member suitably of hook form as well known in the art. The hanger recesses may be reinforced by metal as desired.

With the two basic refractory bricks placd in the position of FIGURE 6 one on top of another and the hanger engaged between them, a channel-shaped oxidizable metallic plate 37' having the base 3S of the channel covering the exposed broad face of the brick 22Sr and having long `arms dl of the channel is fitted down over and closely conforming to the outsides of the two bricks as illustrated, so that it lsurrounds the lateral sides of both bricks and then is secured as by spot welding lat 36 to the tabs 2-2 of the plate 2d already secured to the brick 2S by cornolding.

Thus it will be seen that the two bricks 2S and 2S function as a unit, and are suspended by the single hanger 43 .and have only one thickness of plate around the outside and also between them except at the small areas where the tabs 22 are located.

Any suitable number of bricks may be arranged in each group.

In some cases it is preferable to apply comolded plates 29 to both bricks which are to be assembled together rather than only one as shown in FIGURES 5 to 8. As illustrated in FIGURE l2 the bricks are assembled with the plates 29 at remote faces, and then separate oxidizable metallic plates 412 extend across the other lateral faces of the bricks :and are united to the tabs 22 of the comolded plates by welds 36.

Thus it will be evident that the plate structure which is added to the assembled brick pair `or group may be `a single plate or a group of plates as desired.

In view of my invention and disclosure, variations and modifica-tions to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefits of my invention without copying the structure and method shown, and I, therefore, claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Having thus described my invention what I claim as new and desire to secure by Letters Patent is:

1. A basic refractory brick combination comprising two separate basic refractory bricks each of which has first, second, third and fourth lateral llongitudinal faces,

the first lateral longitudinal face of the first brick being in face-to-face adjacent relation with the third lateral longitudinal face of the second brick, a first oxidizable metallic plate having a base, supporting projecting tabs between opposed edges of the base and projecting arms at the edges of the base, said base being in abutting relation with the first lateral longitudinal face of the second brick which is opposite to said third iateral longitudinal face of the second brick, said projecting .tabs and projecting arms being securely embedded in the refractory of the second brick and said projecting arms having outside faces which are flush with the second and fourth lateral longitudinal faces of said second brick which are transverse to said first lateral longitudinal face of said second brick, said :arms extending substantially less than the transverse dimension of said second and fourth lateral 4longitudinal faces `of said second brick, said second and fourth lateral longitudinal faces of said second brick being opposed to one another, Iand :a second separate oxidizable metallic plate of U cross section having a base of the U directly abutting said third lateral longitudinal face of said first brick and having arms of the U abutting substantially the entirety of the facial areas of the second and fourth lateral longitudinal faces of .the first brick which are transverse to said first lateral longitudinal face of the first brick and also abutting the second and fourth lateral longitudinal faces of said second brick, said second plate extending over the outside faces `of said projecting arms of the oxidizable metall-ic plate first mentioned and being anchored to the body of the second brick by said first plate, said second plate being bonded to said projecting arms so that said first and second plates encase all the outside lateral longitudinal faces of the first and second brick `and are retained as `a casing `on the refractory by said projecting arms.

2. A basic refractory brick combination comprising two separate basic refractory brick-s each of which has first, second, third and fourth lateral longitudinal faces, the first lateral longitudinal face of the first brick being in face-to-face adjacent relation with the third lateral longitudinal face of the second brick, a first oxidizable metallic plate having a base, supporting projecting tabs between opposed edges of the base and projecting arms at the edges of the base, said base being in abutting relation with the first lateral longitudinal face of the second brick which is opposite to said third lateral longitudinal face of the second brick, said projecting tabs and projecting arms being securely embedded in the refractory of the second `brick and said projecting arms having outside faces which are fiush with the second and fourth lateral longitudinal faces of said second brick which are transverse to said first lateral longitudinal face of said second brick, said arms extending substantially less than the transverse dimension of said second and fourth lateral longitudinal faces of said second brick, said second and fourth lateral longitudinal faces of 4said second brick being opposed to one another, a second separate oxidizable metallic plate of U cross section having a base of the U directly abutting said third lateral longitudinal face of said first brick and having arms of the U abutting substantially the entirety of the facial areas of the second and fourth lateral longitudinal faces of the first brick which `are transverse to said rst lateral longitudinal face of `the first brick and also abutting the second and fourth lateral longitudinal faces of said second brick, said second plate extending over the outside faces of said projecting arms of Athe oxidizable metallic plate first ment-ioned and being `anchored to the body of the second brick by said first plate, said second plate being bonded to said projecting arms so that said first and second plates encase all the outside lateral longitudinal faces of the first and second brick and are retained as a casing on the refractory by said projecting arms, and a third oxidizable metallic plate interposed between the first lateral .longitudinal face of the first brick and the third lateral longitudinal face of .the second brick.

3. A basic refractory'brick combination comprising first Iand second basic refractory bricks each of which has first, second, third and fourth lateral longitudinal faces, the first lateral longitudinal face of .the first brick being in abutting relation to the third lateral longitudinal face of the second brick, a first oxidizable metallic plate having a base abutting against the thind later-al longitudinal face of the first brick which is opposite to the third lateral longitudinal face of the first brick, said first plate having projecting arms on opposed edges of the base and supporting projecting tabs between said :opposed edges of the base, said projecting tabs yand projecting arms being securely embedded in the refractory body of said first brick and said projecting arms yhaving outside faces flush with said second and fourth lateral longitudinal faces of said first brick which are transverse to the first and :third laterall longitudinal faces of said first brick, said arms extending substantially less than the transverse dimension of said second 'and fourth lateral longitudinal faces of said firs-t brick, a second oxidizable metallic pla/te having la base abutting against the first lateral longitudinal face of the second brick which is opposite to the third lateral longitudinal face of Ithe second brick, said second plate having projecting arms on opposed edges of the base and supporting projecting tabs between said opposed edges of the base, said projecting tabs and .projecting arms being securely embedded in the refractory of the second brick, said projecting arms having outside faces flush with the second and fourth lateral longitudinal faces of the second brick which are transverse to the first and third lateral longitudinal faces of the second brick, a third oxidizable metallic plate which abuts against substantial-ly the entire second faces of the first and second bricks, and extends over projecting arms of the first and second plate `at those faces and is anchored to the first and second bricks by said first and second plates, said third oxidizable metallic plate being bonded to said projecting yarms of said first and second plates, and a fourth oxidizable metallic plate which is abutting against substantially the entire fourth lateral 1ongitudinal faces yof said first `and second bricks and which extends over the outside of the projecting arms of said first and second oxidizable metallic plates which are on the fourth lateral longitudinal faces of the first and secondbricks, said fourth oxidizable metallic plate being anchored to the first yand second bricks by said iirst and second plates and said fourth oxidizable metallic plates being bonded to said projecting wins of said first and second plates, said first, second, third and fourth oxidizable metallic platestogether comprising ya casing which extends all around the outside lateral longitudinal faces of the first and second bricks and retains them together as a combination.

References Cited in the file of this patent UNlTED STATES PATENTS 1,845,711 Honig et al. Feb. 6, 1932 2,155,165 Heuer Apr. 13, 1939 2,304,170 Heuer Dec. 8, 1942 2,465,170 Rochow Mar. 22, 1949 2,736,187 Coffman et al Feb. 28, 1956 2,764,887 DAmbly Oct. 2, 1956 2,846,963 Mason Aug. 12, 1958 2,960,948 Garetts Nov. 15, 1960 

1. A BASIC REFRACTORY BRICK COMBINATION COMPRISING TWO SEPARATE BASIC REFRACTORY BRICKS EACH OF WHICH HAS FIRST, SECOND, THIRD AND FOURTH LATERAL LONGITUDINAL FACES, THE FIRST LATERAL LONGITUDINAL FACE OF THE FIRST BRICK BEING IN FACE-TO-FACE ADJACENT RELATION WITH THE THIRD LATERAL LONGITUDINAL FACE OF THE SECOND BRICK, A FIRST OXIDIZABLE METALLIC PLATE HAVING A BASE, SUPPORTING PROJECTING TABS BETWEEN OPPOSED EDGES OF THE BASE AND PROJECTING ARMS AT THE EDGES OF THE BASE, SAID BASE BEING IN ABUTTING RELATION WITH THE FIRST LATERAL LONGITUDINAL FACE OF THE SECOND BRICK WHICH IS OPPOSITE TO SAID THIRD LATERAL LONGITUDINAL FACE OF THE SECOND BRICK, SAID PROJECTING TABS AND PROJECTING ARMS BEING SECURELY EMBEDDED IN THE REFRACTORY OF THE SECOND BRICK AND SAID PROJECTING ARMS HAVING OUTSIDE FACES WHICH ARE FLUSH WITH THE SECOND AND FOURTH LATERAL LONGITUDINAL FACES OF SAID SECOND BRICK WHICH ARE TRANSVERSE TO SAID FIRST LATERAL LONGITUDINAL FACE OF SAID SECOND BRICK, SAID ARMS EXTENDING SUBSTANTIALLY LESS THAN THE TRANSVERSE DIMENSION OF SAID SECOND AND FOURTH LATERAL LONGITUDINAL FACES OF SAID SECOND BRICK, SAID SECOND AND FOURTH LATERAL LONGITUDINAL FACES OF SAID SECOND BRICK BEING OPPOSED TO ONE ANOTHER, AND A SECOND SEPARATE OXIDIZABLE METALLIC PLATE OF U CROSS SECTION HAVING A BASE OF THE U DIRECTLY ABUTTING SAID THIRD LATERAL LONGITUDINAL FACE OF SAID FIRST BRICK AND HAVING ARMS OF THE U ABUTTING SUBSTANTIALLY THE ENTIRETY OF THE FACIAL AREAS OF THE SECOND AND FOURTH LATERAL LONGITUDINAL FACES OF THE FIRST BRICK WHICH ARE TRANSVERSE TO SAID FIRST LATERAL LONGITUDINAL FACE OF THE FIRST BRICK AND ALSO ABUTTING THE SECOND AND FOURTH LATERAL LONGITUDINAL FACES OF SAID SECOND BRICK, SAID SECOND PLATE EXTENDING OVER THE OUTSIDE FACES OF SAID PROJECTING ARMS OF THE OXIDIZABLE METALLIC PLATE FIRST MENTIONED AND BEING ANCHORED TO THE BODY OF THE SECOND BRICK BY SAID FIRST PLATE, SAID SECOND PLATE BEING BONDED TO SAID PROJECTING ARMS SO THAT SAID FIRST AND SECOND PLATES ENCASE ALL THE OUTSIDE LATERAL LONGITUDINAL FACES OF THE FIRST AND SECOND BRICK AND ARE RETAINED AS A CASING ON THE REFRACTORY BY SAID PROJECTING ARMS. 